Lightweight Torsen style limited slip differential and rear driveline package for Formula SAE

Abstract

This document describes the design and fabrication of a complete driveline package for the MIT Formula SAE race car. The driveline is centered around a custom aluminum housing for a Torsen® T 1I gearing. This gearing provides a torque biases limited slip differential which has had good success in the Formula SAE series. The design includes all of the components needed to deliver power from a Honda CBR600 F4i engine to the wheels of a custom race car. This document is intended to document the design process that went into the 2006 MIT FSAE car. Furthermore, this document describes many of the steps required to manufacture each component. FSAE competitors often face the challenge of fabricating the parts that they design. Manufacturing setups are shown and described in order to help designers best prepare for fabrication.